ESAB M3® Plasma G2 User manual

Category
Welding System
Type
User manual

This manual is also suitable for

m3 G2 (ICH) Plasma System
Instruction Manual
0558011509 07/2014
(use with EPP-201/360/450/601 Power Sources)
3
m3 G2 (ICH) Plasma System
This equipment will perform in conformity with the description thereof contained in this manual and accompa-
nying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instruc-
tions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment
should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced imme-
diately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone
or written request for service advice be made to the Authorized Distributor from whom it was purchased.
This equipment or any of its parts should not be altered without the prior written approval of the manufacturer.
The user of this equipment shall have the sole responsibility for any malfunction which results from improper
use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a ser-
vice facility designated by the manufacturer.
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the
principles of operation and safe practices for arc welding and cutting equipment, we urge
you to read our booklet, “Precautions and Safe Practices for Arc Welding, Cutting, and
Gouging,” Form 52-529. Do NOT permit untrained persons to install, operate, or maintain
this equipment. Do NOT attempt to install or operate this equipment until you have read
and fully understand these instructions. If you do not fully understand these instructions,
contact your supplier for further information. Be sure to read the Safety Precautions be-
fore installing or operating this equipment.
USER RESPONSIBILITY
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
PROTECT YOURSELF AND OTHERS!
CAUTION
Be sure this information reaches the operator.
You can get extra copies through your supplier.
SAFETY
13
1.0 Safety - English
WARNING: These Safety Precautions are
for your protection. They summarize
precautionary information from the
references listed in Additional Safety
Information section. Before performing any instal-
lation or operating procedures, be sure to read and
follow the safety precautions listed below as well
as all other manuals, material safety data sheets,
labels, etc. Failure to observe Safety Precautions
can result in injury or death.
PROTECT YOURSELF AND OTHERS --
Some welding, cutting, and gouging
processes are noisy and require ear
protection. The arc, like the sun, emits
ultraviolet (UV) and other radiation and can injure
skin and eyes. Hot metal can cause burns. Training
in the proper use of the processes and equipment
is essential to prevent accidents. Therefore:
1. Always wear safety glasses with side shields in
any work area, even if welding helmets, face
shields, and goggles are also required.
2. Use a face shield tted with the correct lter and
cover plates to protect your eyes, face, neck, and
ears from sparks and rays of the arc when oper-
ating or observing operations. Warn bystanders
not to watch the arc and not to expose themselves
to the rays of the electric-arc or hot metal.
3. Wear ameproof gauntlet type gloves, heavy
long-sleeve shirt, cuess trousers, high-topped
shoes, and a welding helmet or cap for hair
protection, to protect against arc rays and hot
sparks or hot metal. A ameproof apron may also
be desirable as protection against radiated heat
and sparks.
4. Hot sparks or metal can lodge in rolled up sleeves,
trouser cus, or pockets. Sleeves and collars
should be kept buttoned, and open pockets
eliminated from the front of clothing.
5. Protect other personnel from arc rays and hot
sparks with a suitable non-ammable partition
or curtains.
6. Use goggles over safety glasses when chipping
slag or grinding. Chipped slag may be hot and
can y far. Bystanders should also wear goggles
over safety glasses.
FIRES AND EXPLOSIONS -- Heat from
ames and arcs can start res. Hot
slag or sparks can also cause res and
explosions. Therefore:
1. Remove all combustible materials well away from
the work area or cover the materials with a pro-
tective non-ammable covering. Combustible
materials include wood, cloth, sawdust, liquid
and gas fuels, solvents, paints and coatings,
paper, etc.
2. Hot sparks or hot metal can fall through cracks
or crevices in oors or wall openings and cause a
hidden smoldering re or res on the oor below.
Make certain that such openings are protected
from hot sparks and metal.“
3. Do not weld, cut or perform other hot work until
the work piece has been completely cleaned so
that there are no substances on the work piece
which might produce ammable or toxic vapors.
Do not do hot work on closed containers. They
may explode.
4. Have re extinguishing equipment handy for
instant use, such as a garden hose, water pail,
sand bucket, or portable re extinguisher. Be
sure you are trained in its use.
5. Do not use equipment beyond its ratings. For
example, overloaded welding cable can overheat
and create a re hazard.
6. After completing operations, inspect the work
area to make certain there are no hot sparks or
hot metal which could cause a later re. Use re
watchers when necessary.
7. For additional information, refer to NFPA Stan-
dard 51B, "Fire Prevention in Use of Cutting and
Welding Processes", available from the National
Fire Protection Association, Battery march Park,
Quincy, MA 02269.
ELECTRICAL SHOCK -- Contact with
live electrical parts and ground can
cause severe injury or death. DO NOT
use AC welding current in damp areas,
if movement is conned, or if there is
danger of falling.
SAFETY
SAFETY
14
1. Be sure the power source frame (chassis) is con-
nected to the ground system of the input power.
2. Connect the work piece to a good electrical ground.
3. Connect the work cable to the work piece. A poor
or missing connection can expose you or others
to a fatal shock.
4. Use well-maintained equipment. Replace worn or
damaged cables.
5. Keep everything dry, including clothing, work area,
cables, torch/electrode holder, and power source.
6. Make sure that all parts of your body are insulated
from work and from ground.
7. Do not stand directly on metal or the earth while
working in tight quarters or a damp area; stand
on dry boards or an insulating platform and wear
rubber-soled shoes.
8. Put on dry, hole-free gloves before turning on the
power.
9. Turn o the power before removing your gloves.
10. Refer to ANSI/ASC Standard Z49.1 (listed on
next page) for specic grounding recommenda-
tions. Do not mistake the work lead for a ground
cable.
ELECTRIC AND MAGNETIC FIELDS — May be
dangerous. Electric current owing through any
conductor causes localized Electric
and Magnetic Fields (EMF). Weld-
ing and cutting current creates EMF
around welding cables and welding
machines. Therefore:
1. Welders having pacemakers should consult their
physician before welding. EMF may interfere with
some pacemakers.
2. Exposure to EMF may have other health eects which
are unknown.
3. Welders should use the following procedures to
minimize exposure to EMF:
A. Route the electrode and work cables together.
Secure them with tape when possible.
B. Never coil the torch or work cable around your
body.
C. Do not place your body between the torch and
work cables. Route cables on the same side of
your body.
D. Connect the work cable to the work piece as close
as possible to the area being welded.
E. Keep welding power source and cables as far
away from your body as possible.
FUMES AND GASES -- Fumes and
gases, can cause discomfort or harm,
particularly in conned spaces. Do
not breathe fumes and gases. Shield-
ing gases can cause asphyxiation.
Therefore:
1. Always provide adequate ventilation in the work area
by natural or mechanical means. Do not weld, cut, or
gouge on materials such as galvanized steel, stain-
less steel, copper, zinc, lead, beryllium, or cadmium
unless positive mechanical ventilation is provided.
Do not breathe fumes from these materials.
2. Do not operate near degreasing and spraying opera-
tions. The heat or arc rays can react with chlorinated
hydrocarbon vapors to form phosgene, a highly
toxic gas, and other irritant gases.
3. If you develop momentary eye, nose, or throat ir-
ritation while operating, this is an indication that
ventilation is not adequate. Stop work and take
necessary steps to improve ventilation in the work
area. Do not continue to operate if physical discom-
fort persists.
4. Refer to ANSI/ASC Standard Z49.1 (see listing below)
for specic ventilation recommendations.
SAFETY
SAFETY
15
5. WARNING: This product, when used for welding
or cutting, produces fumes or gases which con-
tain chemicals known to the State of California
to cause birth defects and, in some cases, can-
cer. (California Health & Safety Code §25249.5
et seq.)
CYLINDER HANDLING -- Cylinders,
if mishandled, can rupture and vio-
lently release gas. Sudden rupture
of cylinder, valve, or relief device can
injure or kill. Therefore:
1. Use the proper gas for the process and use the
proper pressure reducing regulator designed to
operate from the compressed gas cylinder. Do not
use adaptors. Maintain hoses and ttings in good
condition. Follow manufacturer's operating instruc-
tions for mounting regulator to a compressed gas
cylinder.
2. Always secure cylinders in an upright position by
chain or strap to suitable hand trucks, undercar-
riages, benches, walls, post, or racks. Never secure
cylinders to work tables or xtures where they may
become part of an electrical circuit.
3. When not in use, keep cylinder valves closed. Have
valve protection cap in place if regulator is not con-
nected. Secure and move cylinders by using suitable
hand trucks. Avoid rough handling of cylinders.
4. Locate cylinders away from heat, sparks, and ames.
Never strike an arc on a cylinder.
5. For additional information, refer to CGA Standard P-1,
"Precautions for Safe Handling of Compressed Gases
in Cylinders", which is available from Compressed
Gas Association, 1235 Jeerson Davis Highway,
Arlington, VA 22202.
EQUIPMENT MAINTENANCE -- Faulty or im-
properly maintained equipment can cause
injury or death. Therefore:
1. Always have qualied personnel perform the instal-
lation, troubleshooting, and maintenance work.
Do not perform any electrical work unless you are
qualied to perform such work.
2. Before performing any maintenance work inside a
power source, disconnect the power source from
the incoming electrical power.
3. Maintain cables, grounding wire, connections, power
cord, and power supply in safe working order. Do
not operate any equipment in faulty condition.
4. Do not abuse any equipment or accessories. Keep
equipment away from heat sources such as furnaces,
wet conditions such as water puddles, oil or grease,
corrosive atmospheres and inclement weather.
5. Keep all safety devices and cabinet covers in position
and in good repair.
6. Use equipment only for its intended purpose. Do
not modify it in any manner.
ADDITIONAL SAFETY INFORMATION -- For more
information on safe practices for electric
arc welding and cutting equipment, ask
your supplier for a copy of "Precautions
and Safe Practices for Arc Welding, Cut-
ting and Gouging", Form 52-529.
The following publications, which are available from
the American Welding Society, 550 N.W. LeJuene Road,
Miami, FL 33126, are recommended to you:
1. ANSI/ASC Z49.1 - “Safety in Welding and Cutting”.
2. AWS C5.1 - “Recommended Practices for Plasma Arc
Welding”.
3. AWS C5.2 - “Recommended Practices for Plasma Arc
Cutting.
4. AWS C5.3 - “Recommended Practices for Air Carbon
Arc Gouging and Cutting.
5. AWS C5.5 - “Recommended Practices for Gas Tung-
sten Arc Welding“.
6. AWS C5.6 - “Recommended Practices for Gas Metal
Arc Welding”.
7. AWS SP - “Safe Practices” - Reprint, Welding Hand-
book.
8. ANSI/AWS F4.1, “Recommended Safe Practices for
Welding and Cutting of Containers That Have Held
Hazardous Substances.
9. CSA Standard - W117.2 = Safety in Welding, Cutting
and Allied Processes.
SAFETY
SAFETY
16
The IP code indicates the enclosure class, i.e. the degree of protection against penetration by solid objects or
water. Protection is provided against touch with a nger, penetration of solid objects greater than 12mm and
against spraying water up to 60 degrees from vertical. Equipment marked IP21S may be stored, but is not
intended to be used outside during precipitation unless sheltered.
Enclosure Class
This product is solely intended for plasma cutting. Any other use may
result in personal injury and / or equipment damage.
15°
Maximum
Tilt Allowed
CAUTION
If equipment is placed on a surface that slopes more
than 1, toppling over may occur. Personal injury and
/ or signicant damage to equipment is possible.
CAUTION
To avoid personal injury and/or equipment damage,
lift using method and attachment points shown here.
CAUTION
CAUTION
CAUTION
Means immediate hazards which, if not avoided, will result in immediate,
serious personal injury or loss of life.
Means potential hazards which could result in personal injury or loss of life.
Means hazards which could result in minor personal injury.
MEANING OF SYMBOLS - As used throughout this manual: Means Attention! Be Alert! Your
safety is involved.
WARNING
DANGER
CAUTION
SAFETY
SAFETY
23
1. Eorcez-vous de toujours coner les tâches d'installation,
de dépannage et d'entretien à un personnel qualié.
N'eectuez aucune réparation électrique à moins d'être
qualié à cet eet.
2. Avant de procéder à une tâche d'entretien à l'intérieur
de la source d'alimentation, débranchez l'alimentation
électrique.
3. Maintenez les câbles, les ls de mise à la terre, les
branchements, le cordon d'alimentation et la source
d'alimentation en bon état. N'utilisez jamais un équipe-
ment s'il présente une défectuosité quelconque.
4. N'utilisez pas l'équipement de façon abusive. Gardez
l'équipement à l'écart de toute source de chaleur,
notamment des fours, de l'humidité, des aques d'eau,
de l'huile ou de la graisse, des atmosphères corrosives et
des intempéries.
5. Laissez en place tous les dispositifs de sécurité et tous les
panneaux de la console et maintenez-les en bon état.
6. Utilisez l'équipement conformément à son usage prévu
et n'eectuez aucune modication.
INFORMATIONS SUPPLÉMENTAIRES RELATIVES À LA
SÉCURITÉ -- Pour obtenir de l'information
supplémentaire sur les règles de sécurité à
observer pour l'équipement de soudage à
l'arc électrique et le coupage, demandez un exem-
plaire du livret "Precautions and Safe Practices for
Arc Welding, Cutting and Gouging", Form 52-529.
Les publications suivantes sont également recomman-
dées et mises à votre disposition par l'American Weld-
ing Society, 550 N.W. LeJuene Road, Miami, FL 33126 :
5. AVERTISSEMENT : Ce produit, lorsqu'il est utilisé
dans une opération de soudage ou de coupage,
dégage des vapeurs ou des gaz contenant des
chimiques considéres par l'état de la Californie
comme étant une cause des malformations
congénitales et dans certains cas, du cancer.
(California Health & Safety Code §25249.5 et
seq.)
MANIPULATION DES CYLINDRES --
La manipulation d'un cylindre, sans
observer les précautions nécessaires,
peut produire des fissures et un
échappement dangereux des gaz.
Une brisure soudaine du cylindre, de la
soupape ou du dispositif de surpression peut causer
des blessures graves ou mortelles. Par conséquent :
1. Utilisez toujours le gaz prévu pour une opération et le
détendeur approprié conçu pour utilisation sur les cyl-
indres de gaz comprimé. N'utilisez jamais d'adaptateur.
Maintenez en bon état les tuyaux et les raccords. Observez
les instructions d'opération du fabricant pour assembler
le détendeur sur un cylindre de gaz comprimé.
2. Fixez les cylindres dans une position verticale, à l'aide
d'une chaîne ou une sangle, sur un chariot manuel, un
châssis de roulement, un banc, un mur, une colonne ou
un support convenable. Ne xez jamais un cylindre à un
poste de travail ou toute autre dispositif faisant partie
d'un circuit électrique.
3. Lorsque les cylindres ne servent pas, gardez les soupapes
fermées. Si le détendeur n'est pas branché, assurez-vous
que le bouchon de protection de la soupape est bien en
place. Fixez et déplacez les cylindres à l'aide d'un chariot
manuel approprié. Toujours manipuler les cylindres avec
soin.
4. Placez les cylindres à une distance appropriée de toute
source de chaleur, des étincelles et des ammes. Ne jamais
amorcer l'arc sur un cylindre.
5. Pour de l'information supplémentaire, consultez CGA
Standard P-1, "Precautions for Safe Handling of Com-
pressed Gases in Cylinders", mis à votre disposition par
le Compressed Gas Association, 1235 Jeerson Davis
Highway, Arlington, VA 22202.
ENTRETIEN DE L'ÉQUIPEMENT -- Un équipe-
ment entretenu de façon défectueuse ou
inadéquate peut causer des blessures
graves ou mortelles. Par conséquent :
1. ANSI/ASC Z49.1 - “Safety in Welding and Cutting”.
2. AWS C5.1 - “Recommended Practices for Plasma Arc
Welding”.
3. AWS C5.2 - “Recommended Practices for Plasma Arc
Cutting.
4. AWS C5.3 - “Recommended Practices for Air Carbon
Arc Gouging and Cutting.
5. AWS C5.5 - “Recommended Practices for Gas Tung-
sten Arc Welding“.
6. AWS C5.6 - “Recommended Practices for Gas Metal
Arc Welding”.
7. AWS SP - “Safe Practices - Reprint, Welding Hand-
book.
8. ANSI/AWS F4.1, “Recommended Safe Practices for
Welding and Cutting of Containers That Have Held
Hazardous Substances.
9. CSA Standard - W117.2 = Safety in Welding, Cutting
and Allied Processes.
SAFETY
DESCRIPTION
26
ABBREVIATIONS:
m3 G2 - m3 Generation 2
A/C - Air Curtain
AHC - Automatic Height Control
ICH - Interface Control Hub
PGC - Plasma Gas Control
SGC - Shield Gas Control
WIC - Water Injection Control
Below are some abbreviations used throughout this manual.
DESCRIPTION
DESCRIPTION
27
2.0 System Diagrams
The following pages illustrate dierent system congurations available on the m3 Generation 2 (m3 G2). With
this system, ESAB oers 8 dierent congurations to meet customers requirements. Below are the descriptions
of each conguration.
1. Base System
This system is the basic conguration for the m3 G2 Plasma System. It contains the major components, such as the
Power Supply (EPP201/360/450/601), Coolant Circulator, PT-36 Torch, Remote Arc Starter (RAS), Plasma Gas Control
(PGC), Shield Gas Control (SGC), and Interface Control Hub (ICH). This system will meet most customers’ needs in
cutting carbon steel, stainless steel, and aluminum. It also has the functionality of marking on carbon steel and
stainless steel with the same torch and the same consumables. By simply alternating cutting and marking mode on
the y, this system is capable of cutting and marking in the same part program without changing the consumables.
To use this system, customer CNC needs to send start signal and corner signal while in geometric corner; at the
same time, customer CNC needs to monitor the fault signal and motion enable signal from ICH. This base system
does not come with Automatic Height Control (AHC). Customer will have to provide AHC and control its sequence.
2. Base System + AHC
This system includes the Base System plus the ESAB AHC, called a “B4 lifter”. In this conguration, ICH will control
plasma sequence, and also the AHC sequence. Customer CNC needs to provide the start signal and corner signal
for normal cutting.
3. Base System + A/C
This system includes the above Base System and ESAB Air Curtain (A/C). Air Curtain is a device used to improve the
performance of plasma arc when cutting underwater. ICH from the Base System will control the sequence and turn
on/o the air.
4. Base System + WIC
This system is congured to introduce the Water Injection Control (WIC), a module used to regulate cut water ow
to shield the cutting process. This conguration is to meet needs of a customer who wants to cut stainless steel
without using H35. This system still uses the standard PT-36 torch, but a dierent set of consumables. Similar to the
dry system, this WIC system can also do marking with water shield.
5. Base System + AHC + WIC
This system provides customer the Base System, AHC (Automatic Height Control), and WIC (Water Injection
Control). With this system, customer needs only to provide start signal and corner signal for cutting stainless steel
with water injection.
6. Base System + AHC + A/C
This system gives the customer the ability to cut under water with ESAB Automatic Height Control (AHC).
7. Base System + WIC + A/C
This system is the Base System adding Water Injection Control (WIC) and Air Curtain (A/C). Customer needs to
provide their own Height Control and control its sequence.
8. Base System + AHC + WIC + A/C
This complete system gives the opportunity for customer to cut carbon steel, stainless steel, and aluminum with
ESAB Auto Height Control (AHC). Customer has the capability to cut stainless steel with the Water Injection Control
(WIC), and underwater with the help of Air Curtain (A/C).
DESCRIPTION
Base System
CC-IC
PS-IC
PS & CC Control Cable
Power Cable
Pilot Arc Cable
Coolant Supply Hose
Ext. E-Stop
Digital I/O
(Must be 230V
with
AHC)
Ext. 115/230V
RAS-TC IN
Air
N
2
O2
CH4
H35
Ar
SGC-SG
SGC-PWR
SGC-PG1
SGC-PG2
SGC-Air
SGC-N
2
SGC-O2
SGC-CH4
RAS-E-Stop
RAS-CAN
Power, Pilot Arc, Coolant
RAS -VDR
Shield Gas Hose
Plasma Gas
Hose
PGC-PG1
PGC-PG2
PGC-H
35
PGC-Ar
PGC-CAN
Manual # 0558007865 - Rev.0 1/2008
Service Manual
This manual provides service / troubleshooting
instructions for CC11 consoles beginning with
AORJ735024 models.
CC11
COOLANT
CIRCULATOR
PN 0558007515
ICH-RAS CAN
ICH-SGC CAN
ICH-PGC CAN
ICH-AC1
RAS-TC OUT
RAS-PA
RAS-E(
-)
RAS-PSC
PS-PA
PS-E(
-)
PS-PSC
Coolant Return Hose
Gas Controls Power Cable
SGC-CAN
SGC-A/C IN
CC-TC OUT
CC-TC IN
PT-36 Torch
SGC
(Shield Gas Control)
RAS
(Remote Arc Starter)
PGC
(Plasma Gas Control)
CC
(Coolant Circulator)
PS
(Power Supply)
ICH
(Interface Control Hub)
PGC-PWR
Customer
CNC
R
m3 G2 Systems
Interconnect Diagram
BOLD FONT = Cable Connection Label
POWER
DATA
LIQUID
GAS
Optional
R
G2 Base System
ICH-IO
ICH-PWR
AHC-VDR
CUSTOMER
AHC
Base System + AHC
CC-IC
PS-IC
PS & CC Control Cable
Power Cable
Pilot Arc Cable
Coolant Supply Hose
Ext. E-Stop
Digital I/O
(Must be 230V
with
AHC)
Ext. 115/230V
RAS-TC IN
Air
N
2
O2
CH4
H35
Ar
SGC-SG
SGC-PWR
SGC-PG1
SGC-PG2
SGC-Air
SGC-N
2
SGC-O2
SGC-CH4
RAS-E-Stop
RAS-CAN
Power, Pilot Arc, Coolant
Shield Gas Hose
Plasma Gas
Hose
PGC-PG1
PGC-PG2
PGC-H
35
PGC-Ar
PGC-CAN
Manual # 0558007865 - Rev.0 1/2008
Service Manual
This manual provides service / troubleshooting
instructions for CC11 consoles beginning with
AORJ735024 models.
CC11
COOLANT
CIRCULATOR
PN 0558007515
ICH-RAS CAN
ICH-SGC CAN
ICH-PGC CAN
ICH-AC1
RAS-TC OUT
RAS-PA
RAS-E(
-)
RAS-PSC
PS-PA
PS-E(
-)
PS-PSC
Coolant Return Hose
Gas Controls Power Cable
SGC-CAN
SGC-A/C IN
CC-TC OUT
CC-TC IN
PT-36 Torch
SGC
(Shield Gas Control)
RAS
(Remote Arc Starter)
PGC
(Plasma Gas Control)
CC
(Coolant Circulator)
PS
(Power Supply)
ICH
(Interface Control Hub)
PGC-PWR
Customer
CNC
R
m3 G2 Systems
Interconnect Diagram
BOLD FONT = Cable Connection Label
POWER
DATA
LIQUID
GAS
Optional
R
G2 Base System +
AHC
ICH-IO
ICH-PWR
RAS -VDR
AHC- AC IN
AHC-CAN
ICH-AC2
ICH-AHC CAN
AHC Power Cable
AHC-VDR
Base System + A/C
CC-IC
PS-IC
PS & CC Control Cable
Power Cable
Pilot Arc Cable
Coolant Supply Hose
Ext. E-Stop
Digital I/O
(Must be 230V
with
AHC)
Ext. 115/230V
RAS-TC IN
Air
N
2
O2
CH4
H35
Ar
SGC-A/C OUT
SGC-SG
SGC-PWR
SGC-PG1
SGC-PG2
SGC-Air
SGC-N
2
SGC-O2
SGC-CH4
RAS-E-Stop
RAS-CAN
Power, Pilot Arc, Coolant
RAS -VDR
Air Curtain
Hose
Shield Gas Hose
Plasma Gas
Hose
PGC-PG1
PGC-PG2
PGC-H
35
PGC-Ar
PGC-CAN
Manual # 0558007865 - Rev.0 1/2008
Service Manual
This manual provides service / troubleshooting
instructions for CC11 consoles beginning with
AORJ735024 models.
CC11
COOLANT
CIRCULATOR
PN 0558007515
ICH-RAS CAN
ICH-SGC CAN
ICH-PGC CAN
ICH-AC1
RAS-TC OUT
RAS-PA
RAS-E(
-)
RAS-PSC
PS-PA
PS-E(
-)
PS-PSC
Coolant Return Hose
Gas Controls Power Cable
SGC-CAN
SGC-A/C IN
CC-TC OUT
CC-TC IN
PT-36 Torch
SGC
(Shield Gas Control)
RAS
(Remote Arc Starter)
PGC
(Plasma Gas Control)
CC
(Coolant Circulator)
PS
(Power Supply)
ICH
(Interface Control Hub)
PGC-PWR
Air Curtain
Customer
CNC
R
m3 G2 Systems
Interconnect Diagram
BOLD FONT = Cable Connection Label
POWER
DATA
LIQUID
GAS
Optional
R
G2 Base System +
A/C
ICH-IO
ICH-PWR
AHC-VDR
CUSTOMER
AHC
Base System + WIC
PS & CC Control Cable
Power Cable
Pilot Arc Cable
Coolant Supply Hose
Ext. E-Stop
Digital I/O
(Must be 230V
with
AHC)
Ext. 115/230V
RAS-TC IN
Air
N
2
O2
CH4
H35
Ar
SGC-SG
SGC-PWR
SGC-PG1
SGC-PG2
SGC-Air
SGC-N
2
SGC-O2
SGC-CH4
RAS-E-Stop
RAS-CAN
Power, Pilot Arc, Coolant
RAS -VDR
WIC-H
2O
OUT
Shield Gas Hose
Plasma Gas
Hose
PGC-PG1
PGC-PG2
PGC-H
35
PGC-Ar
PGC-CAN
PN 0558007515
RAS-TC OUT
RAS-PA
RAS-E(
-)
RAS-PSC
PS-PA
PS-E(
-)
PS-PSC
Coolant Return Hose
SGC-CAN
SGC-AC IN
CC-TC OUT
CC-TC IN
PT-36 Torch
SGC
(Shield Gas Control)
RAS
(Remote Arc Starter)
PGC
(Plasma Gas Control)
PGC-PWR
Customer
CNC
BPR
(Back Pressure
Regulator)
WIC
(Water Injection
Control)
230V AC
Manual
0558009491
WIC-Air IN (optional)
WIC-H
2O IN
WIC-AC IN
WIC-CAN
ICH-RAS CAN
ICH-SGC CAN
ICH-PGC CAN
ICH-AC1
ICH-IO
ICH-CAN
ICH-PWR IN
ICH
(Interface Control Hub)
AHC-VDR
CUSTOMER
AHC
R
m3 G2 Systems
Interconnect Diagram
BOLD FONT = Cable Connection Label
POWER
DATA
LIQUID
GAS
Optional
R
G2 Base System +
WIC
CC-IC
PS-IC
Manual # 0558007865 - Rev.0 1/2008
Service Manual
This manual provides service / troubleshooting
instructions for CC11 consoles beginning with
AORJ735024 models.
CC11
COOLANT
CIRCULATOR
CC
(Coolant Circulator)
PS
(Power Supply)
Base System + AHC + WIC
PS & CC Control Cable
Power Cable
Pilot Arc Cable
Coolant Supply Hose
Ext. E-Stop
Digital I/O
(Must be 230V
with
AHC)
Ext. 115/230V
RAS-TC IN
Air
N
2
O2
CH4
H35
Ar
SGC-SG
SGC-PWR
SGC-PG1
SGC-PG2
SGC-Air
SGC-N
2
SGC-O2
SGC-CH4
RAS-E-Stop
RAS-CAN
Power, Pilot Arc, Coolant
RAS -VDR
AHC- AC IN
AHC-CAN
WIC-H
2O
OUT
Shield Gas Hose
Plasma Gas
Hose
PGC-PG1
PGC-PG2
PGC-H
35
PGC-Ar
PGC-CAN
RAS-TC OUT
RAS-PA
RAS-E(
-)
RAS-PSC
PS-PA
PS-E(
-)
PS-PSC
Coolant Return Hose
SGC-CAN
SGC-AC IN
CC-TC OUT
CC-TC IN
PT-36 Torch
SGC
(Shield Gas Control)
RAS
(Remote Arc Starter)
PGC
(Plasma Gas Control)
PGC-PWR
Customer
CNC
AHC-VDR
BPR
(Back Pressure
Regulator)
WIC
(Water Injection
Control)
230V AC
WIC-Air IN (optional)
WIC-H
2O IN
WIC-AC IN
WIC-CAN
ICH-RAS CAN
ICH-SGC CAN
ICH-PGC CAN
ICH-CAN
ICH-IO
ICH-PWR
ICH-AC2
ICH-AHC CAN
ICH-AC1
ICH
(Interface Control Hub)
CC-IC
PS-IC
Manual # 0558007865 - Rev.0 1/2008
Service Manual
This manual provides service / troubleshooting
instructions for CC11 consoles beginning with
AORJ735024 models.
CC11
COOLANT
CIRCULATOR
PN 0558007515
CC
(Coolant Circulator)
PS
(Power Supply)
R
m3 G2 Systems
Interconnect Diagram
BOLD FONT = Cable Connection Label
POWER
DATA
LIQUID
GAS
Optional
R
G2 Base System +
AHC + WIC
Base System + AHC + A/C
CC-IC
PS-IC
PS & CC Control Cable
Power Cable
Pilot Arc Cable
Coolant Supply Hose
Ext. E-Stop
Digital I/O
(Must be 230V
with
AHC)
Ext. 115/230V
RAS-TC IN
Air
N
2
O2
CH4
H35
Ar
SGC-A/C OUT
SGC-SG
SGC-PWR
SGC-PG1
SGC-PG2
SGC-Air
SGC-N
2
SGC-O2
SGC-CH4
RAS-E-Stop
RAS-CAN
Power, Pilot Arc, Coolant
Air Curtain
Hose
Shield Gas Hose
Plasma Gas
Hose
PGC-PG1
PGC-PG2
PGC-H
35
PGC-Ar
PGC-CAN
Manual # 0558007865 - Rev.0 1/2008
Service Manual
This manual provides service / troubleshooting
instructions for CC11 consoles beginning with
AORJ735024 models.
CC11
COOLANT
CIRCULATOR
PN 0558007515
ICH-RAS CAN
ICH-SGC CAN
ICH-PGC CAN
ICH-AC1
RAS-TC OUT
RAS-PA
RAS-E(
-)
RAS-PSC
PS-PA
PS-E(
-)
PS-PSC
Coolant Return Hose
Gas Controls Power Cable
SGC-CAN
SGC-A/C IN
CC-TC OUT
CC-TC IN
PT-36 Torch
SGC
(Shield Gas Control)
RAS
(Remote Arc Starter)
PGC
(Plasma Gas Control)
CC
(Coolant Circulator)
PS
(Power Supply)
ICH
(Interface Control Hub)
PGC-PWR
Air Curtain
Customer
CNC
R
m3 G2 Systems
Interconnect Diagram
BOLD FONT = Cable Connection Label
POWER
DATA
LIQUID
GAS
Optional
R
G2 Base System +
AHC + A/C
ICH-IO
ICH-PWR
RAS -VDR
AHC- AC IN
AHC-CAN
ICH-AC2
ICH-AHC CAN
AHC Power Cable
AHC-VDR
Base System + WIC + A/C
PS & CC Control Cable
Power Cable
Pilot Arc Cable
Coolant Supply Hose
Ext. E-Stop
Digital I/O
(Must be 230V
with
AHC)
Ext. 115/230V
RAS-TC IN
Air
N
2
O2
CH4
H35
Ar
SGC-A/C OUT
SGC-SG
SGC-PWR
SGC-PG1
SGC-PG2
SGC-Air
SGC-N
2
SGC-O2
SGC-CH4
RAS-E-Stop
RAS-CAN
Power, Pilot Arc, Coolant
RAS -VDR
WIC-H
2O
OUT
Air Curtain
Hose
Shield Gas Hose
Plasma Gas
Hose
PGC-PG1
PGC-PG2
PGC-H
35
PGC-Ar
PGC-CAN
PN 0558007515
ICH-RAS CAN
ICH-CAN
ICH-SGC CAN
IFH-PGC CAN
ICH-AC1
RAS-TC OUT
RAS-PA
RAS-E(
-)
RAS-PSC
PS-PA
PS-E(
-)
PS-PSC
Coolant Return Hose
SGC-CAN
SGC-AC IN
SGC-A/C IN
CC-TC OUT
CC-TC IN
ICH-IO
ICH-PWR
PT-36 Torch
SGC
(Shield Gas Control)
RAS
(Remote Arc Starter)
PGC
(Plasma Gas Control)
ICH
(Interface Control Hub)
PGC-PWR
Air Curtain
Customer
CNC
BPR
(Back Pressure
Regulator)
WIC
(Water Injection
Control)
230V AC
WIC-Air IN (optional)
WIC-H
2O IN
WIC-AC IN
WIC-CAN
AHC-VDR
CUSTOMER
AHC
R
m3 G2 Systems
Interconnect Diagram
BOLD FONT = Cable Connection Label
POWER
DATA
LIQUID
GAS
Optional
R
G2 Base System +
WIC + A/C
CC-IC
PS-IC
CC
(Coolant Circulator)
PS
(Power Supply)
Base System + AHC + WIC + A/C
PS & CC Control Cable
Power Cable
Pilot Arc Cable
Coolant Supply Hose
Ext. E-Stop
Digital I/O
(Must be 230V
with
AHC)
Ext. 115/230V
RAS-TC IN
Air
N
2
O2
CH4
H35
Ar
SGC-A/C OUT
SGC-SG
SGC-PWR
SGC-PG1
SGC-PG2
SGC-Air
SGC-N
2
SGC-O2
SGC-CH4
RAS-E-Stop
RAS-CAN
Power, Pilot Arc, Coolant
RAS -VDR
AHC- AC IN
AHC-CAN
WIC-H
2O
OUT
Air Curtain
Hose
Shield Gas Hose
Plasma Gas
Hose
PGC-PG1
PGC-PG2
PGC-H
35
PGC-Ar
PGC-CAN
PN 0558007515
ICH-RAS CAN
ICH-AC2
ICH-AHC CAN
ICH-WIC CAN
ICH-SGC CAN
ICH-PGC CAN
ICH-AC1
RAS-TC OUT
RAS-PA
RAS-E(
-)
RAS-PSC
PS-PA
PS-E(
-)
PS-PSC
Coolant Return Hose
SGC-CAN
SGC-AC IN
SGC-A/C IN
CC-TC OUT
CC-TC IN
ICH-IO
ICH-PWR
PT-36 Torch
SGC
(Shield Gas Control)
RAS
(Remote Arc Starter)
PGC
(Plasma Gas Control)
ICH
(Interface Control Hub)
PGC-PWR
Air Curtain
Customer
CNC
AHC-VDR
BPR
(Back Pressure
Regulator)
WIC
(Water Injection
Control)
230V AC
WIC-Air IN (optional)
WIC-H
2O IN
WIC-AC IN
WIC-CAN
R
m3 G2 Systems
Interconnect Diagram
BOLD FONT = Cable Connection Label
POWER
DATA
LIQUID
GAS
Optional
R
G2 Base System +
AHC + WIC + A/C
CC-IC
PS-IC
Manual # 0558007865 - Rev.0 1/2008
Service Manual
This manual provides service / troubleshooting
instructions for CC11 consoles beginning with
AORJ735024 models.
CC11
COOLANT
CIRCULATOR
CC
(Coolant Circulator)
PS
(Power Supply)
DESCRIPTION
36
2.1 Power Supply
The m3 G2 system can use dierent plasma power supplies. ESAB provides the EPP-201/360/450/601, with various input voltages and current
output for your requirements. For details about our power supplies, please refer to the power supplys specic manual.
m3 Plasma Power Supply Input/Output Information
m3 201,
380 / 400V,
50 / 60Hz
m3 360,
380 / 400V,
50 / 60Hz
m3 450
380V
50/60HZ
380V TAPS
m3 450
380V
50/60HZ
400V TAPS
m3 450
400V
50/60HZ
m3 601
380V
50/60HZ
380V TAPS
m3 601
380V
50/60HZ
400V TAPS
m3 601
400V
50/60HZ
Input
Input Voltage (3-Phase) 380 / 400V 380 / 400V 380VAC 380VAC 400VAC 380VAC 380VAC 400VAC
Input Current (3-Phase) 60 / 57A RMS 140 / 132A RMS 167A RMS 167A RMS 159A RMS 217A RMS 217A RMS 206A RMS
Input Frequency 50 / 60 HZ 50 / 60 HZ 50/60 HZ 50/60 HZ 50/60 HZ 50/60 HZ 50/60 HZ 50/60 HZ
Input KVA 39.5 KVA 91.6 KVA 109.9 KVA 109.9 KVA 110.2 KVA 142.8 KVA 142.8 KVA 142.7 KVA
Input Power 35.5 KW 82.5 KW 98.9 KW 98.9 KW 99.1 KW 128.5 KW 128.5 KW 128.4 KW
Input Power Factor 90.0 % 90.0 % 90% 90% 90% 90% 90% 90%
Recommended Input
Power Cable
2/0 AWG 2/0 AWG 2/0 AWG 2/0 AWG 2/0 AWG 4/0 AWG 4/0 AWG 4/0 AWG
Input Fuse (Recommended) 100A 200A 200A 200A 200A 250A 250A 250A
Output
Output Open Circuit Voltage
(OCV) (High Range Cutting)
360 VDC 360 VDC 430VDC 406VDC 427VDC 430VDC 406VDC 427VDC
Output Cutting Range
(100% Duty)
30A to 200A 30A to 360A 35A to 450A 35A to 600A
Output Marking Range
(100% Duty)
10A to 36A 10A to 36A 10A to 100A 10A to 100A
Output Power (100% Duty) 32 KW 72 KW 90 KW 120 KW
Protection Class IP 21 IP 21 IP 21 IP 21
Dimensions 585 x 1040 x 1195 mm 585 x 1040 x 1195 mm 950 x 1050 x 1150 mm 950 x 1050 x 1150 mm
Weight 493 kg 493 kg 850 kg 850 kg
380/400V Power Supplies
DESCRIPTION
DESCRIPTION
37
m3 Plasma Power Supply Input/Output Information
m3 201
460V, 60Hz
m3 201
575V, 60Hz
m3 360
460V, 60Hz
m3 360
575V, 60Hz
m3 450
460V, 60HZ
m3 450
575V, 60HZ
m3 601
460V, 60HZ
m3 601
575V, 60HZ
Input
Input Voltage (3-Phase) 460V 575V 460V 575V 460VAC 575VAC 460VAC 575VAC
Input Current (3-Phase) 51A RMS 41A RMS 115A RMS 92A RMS 138A RMS 110A RMS 179A RMS 143A RMS
Input Frequency 60 HZ 60 HZ 60 HZ 60 HZ 60 HZ 60 HZ 60 HZ 60 HZ
Input KVA 40.6 KVA 40.6 KVA 91.6 KVA 91.6 KVA 110.0 KVA 109.6 KVA 142.6 KVA 142.4 KVA
Input Power 35.5 KW 35.5 KW 82.5 KW 82.5 KW 99.0 KW 98.6 KW 128.4 KW 128.2 KW
Input Power Factor 90.0 % 90.0 % 90.0 % 90.0 % 90% 90% 90% 90%
Recommended Input
Power Cable
2/0 AWG 2/0 AWG 2/0 AWG 2/0 AWG 1/0 AWG 2/0 AWG 1/0 AWG 1/0 AWG
Input Fuse (Recommended) 100A 60A 150A 125A 200A 150A 250A 200A
Output
Output Open Circuit Voltage
(OCV) (High Range Cutting)
360 VDC 360 VDC 431VDC 431VDC
Output Cutting Range
(100% Duty)
30A to 200A 30A to 360A 35A to 450A 35A to 600A
Output Marking Range
(100% Duty)
10A to 36A 10A to 36A 10A to 100A 10A to 100A
Output Power (100% Duty) 32 KW 72 KW 90 KW 120 KW
Protection Class IP 21 IP 21 IP 21 IP 21
Dimensions 585 x 1040 x 1195 mm 585 x 1040 x 1195 mm 950 x 1050 x 1150 mm 950 x 1050 x 1150 mm
Weight 493 kg 493 kg 850 kg 850 kg
460/575V Power Supplies
DESCRIPTION
DESCRIPTION
38
2.2 Coolant Circulator (CC-11)
Specications
Dimensions: 34.00" (864 mm) high x 21.75" (552 mm) wide x 28.00 (711 mm) deep
Weight: 215 lb. dry (97.5 kg) / 249 lb. wet (113 kg)
Pump Type:
Positive displacement, rotary vane type with adjustable by-pass valve (200 psi / 13.8 bars max.),
CW rotation as viewed from nameplate.
Radiator Type: Copper tubing, aluminum nned air-to-water type with galvanized steel frame.
AC Input Voltages
50Hz, 1 Phase Input Power 60Hz, 1 Phase Input Power
200 / 230 / 400 / 460 / 575 V, + / - 10%
AC Input Amperage 9 / 8 / 5 / 4 / 3 Amperes
Pump Capacity
1.60 gpm at 175 psi
(6.0 l/min at 12 bars)
1.60 gpm at 175 psi
(6.0 l/min at 12 bars)
Cooling Capacity @ 1.60 gpm
(6.0 l/min)
16,830 BTU / hr. (4900 watts) 20,200 BTU / hr. (5900 watts)
at 45° F (25° C) temperature dierence between high coolant temperature and ambient air tem-
perature using ESAB coolant p/n 0558004297 (25% propylene glycol / 75% distilled water).
Max. Delivery Pressure 175 psig (12 bars)
Reservoir Capacity 4 gallons (15.2 liters)
The Coolant Circulator (CC-11) recirculates coolant to
cool the torch, electrode and nozzle. For more specif-
ic details, please refer to the CC-11 Instruction manual.
p/n 0558007515
DESCRIPTION
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ESAB M3® Plasma G2 User manual

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Welding System
Type
User manual
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